Fireproofing, insulation and soundproofing material

ABSTRACT

Method for the preparation of a cementitous composition having a cellular structure for protecting steel and other structural elements from fire. By spraying directly upon the desired structural substrate; a composition containing gypsum cement, filler or lightweight aggregates, water, and 1/2 percent to 2 percent by weight of a non ionic detergent such as a polyethylene glycol ether combined with 9 moles of ethylene oxide. This same composition is suitable and useful for thermal insulation and acoustical soundproofing. It can be mixed and applied in well known conventional techniques, such as spraying, casting or trowled. Portland cemenet or magnesia cements may be substituted for gypsum cement with similar results.

1O ti k United States Patent 1191 1111 3,819,388 Cornwell June 25, 1974 1 FIREPROOFING, INSULATIQN A1511) 3,223,082 12/1965 Smith 106/111 SOUNDPROOFING MATERIAL 3,307,588 3/1967 Hylak 106/90 3,573,941 4/1971 Edwards etal. 106/90 [76] lnventor: Charles E. Cornwell, 7104 Marlan Alexandria 22307 Primary Examiner-Delbert E. Gantz [22] Filed: June 5, 1972 Assistant Examiner-James W. Hellwege [21] Appl. No.: 259,742

[57] ABSTRACT [52] U.S. Cl 106/86, 106/90, 106/ 109, Method for the preparation of a cementitous composi- 106/D1G.2 tion having a cellular structure for protecting steel and [51] Int. Cl. C04b 7/02, C04b 11/00 other structural elements from fire. By spraying di- [58] Field of Search 106/89, 90, DIG. 2,86, rectl y P211 the desired structural substrate; a compo- 106/109 sition containing gypsum cement fjuer or Ii htw ight aggregates, water, an percent to 2 percent by [56] References Cited iafioi'ignic dgtergent s u c l 1 a s a Ml- UNITED STATES PATENTS 3H glxgg] ether co rlbined with 9 moles of ethylgne 2 009 146 M935 New 06/86 0x1 c. This same co'rfiposnmnis suitalSle and useful for 23772191 611945 6001851.";81331111111111:13:31: 106,86 ma iaaaiaiiaa and aaaaaiiaai aaaaaaaaaiiaa ii 2,598,980 6/1952 Denning .1 106/86 can be mixed and applied in know" conventional 2,598,981 6/1952 Denning 106/86 techniques, such as spraying, casting or trowled. 2,733,995 2/ 1956 Robinson 106/90 Portland ce gt or magnesia cements may be substi, 2,913,346 11/1959 Hoffman ..106/111 t tfi sumceniewffisimiiar resul 3,008,843 ll/l96l Jolly l06/90 3,147,128 9/1964 Harrell 106/105 4 Claims, N0 Drawings a ,12 f V b W BACKGROUND OF THE INVENTION l. Field of the Invention This invention relates to the preparation of a cementitious composition having a cellular structure that provides a barrier between the substrate and fire. The cellular nature of the composition further provides insulation and soundproofing where required. It is suitable for a lighter weight gypsum wall board with the above mentioned qualities.

2. The Prior Art It has been known in the past to spray a foamed cementitious material over steel for protection and insulation against fire. Such formulations have been described in Checho and Umansky US. Pat. No. 3,522,069 granted on July 28, 1970; Fraser US. Pat. No. 3,458,327 granted on July 29, 1969; Harrell US. Pat. No. 3,147,128 granted on Sept. 1, 1964.

Foamed magnesia cement formulations are well known. Several inventions use a pre-forrned foam, such as Checho and Umansky US. Pat. No. 3,522,069, with their composition, others use a mixing technique to introduce air into the material by agitation and forced air penetrations. However, most of the aeration produced by these various methods are lost during pumping and spraying operations. The introduction of paper fibers, asbestos fibers, rock wool, uncoated fiberglass usually wad or ball up causing pump breakdowns and spraygun jams. When a jam at the spraygun nozzle occurs, there is a fast build up of pressure that immediately breaks SUMMARY OF THE INVENTION In accordance with the invention, a method is provided for adding within the mixture the precise amount of a bubble forming additive known as a non ionic de- Optional (Polyvinyl Acetate) 1.0 5.0 o- 3 Example 2 In r dient Parts by Weight Portland Cement 50 lo vermiculite IO- 45 Water I00 200 Non Ionic Detergent 25 2.0 Optional (Polyvinyl Acetate) l 0 5.0

Example 3 In redient Parts b Wei ht l5 Magnesia y 5 35 Magnesium Salt 5 35 vermiculite 45 Water I00 200 Mon Ionic Detergent 25 2.0 Optional (Polyvinyl Acetate) l O 5.0

air dry havi sities as little as 10 unds er foot to a roximatel 3 on s er The cement to water ratios determine e actual strength of tergent, Tergitol 15559, which consists ofapo lyethylene glycol ether combined with 9 moles of ethylene oxide. This bubble forming agent provides the means for mixing a cementitious composition that forms a cellular structure with equal distribution of the cells throughout the composition.

A uniformed consistency of the density is maintained at all times with the use of this non ionic detergent Example l Parts by Weight In redient Gypsum Cement vermiculite Water -Continued Example I In redient Non Ionic Detergent By adding appropriate proportions of the non ionic detergent to such slurry compositions the material will the composition. The amount of the non ionic detergent determines the cellular content.

The liquid 1 vin lacetatg is added to the composition when required or 'the' purpose of addin rea r adhesion to the surface being prayed; i.e., overhead mtlire'sf'Theaddition of polyvinyl acetate in appropriate proportions does not deter the inherent fireproofing qualities or cellular structure.

The cellular structure of this material has inherent insulating and acoustical values not generally available in other products that are currently used. The spraying, casting or trowled application of this composition lends itself to many applications. Spraying an appropriate thickness of this material over steel will meet ASTM fireproof ratings. When cast or pumped into wall structures, as the inner core, the material provides a fire wall barrier. It further provides acoustical soundproofness that is valuable in homes and commercial buildings, as well as in helping the control of ecological sound transmission or suppression.

The equipment re uired to form this slurry composition is all standard. he mixer can be either the standard paddle mortar mixer or the ribbon type. The rotating drum type is not recommended. Mixing times need not exceed. 2 to 3 minutes per batch.

Spraying this composition is accomplished by pouring the mix into a hopper with connecting pump such as a Clipper P-30, Squeez crete or Essick. These pumps are suitable for the pumping of the material. The Anning-Johnson or R-Tex nozzle is suitable for spraying.

What is claimed is:

l. A cementitious composition havin a dry density in the range of 10-35 pounds per cubic oot comprising 50-100 parts by weight of a cement selected from the group consisting of gypsum and portland cement, 10-45 parts by weight of a light weight mineral aggregate, and one-fourth to two parts by weight of a non ionic detergent.

2. The composition of claim 1 further comprising one to five parts by weight of polyvinyl acetate.

3. The composition of claim 1 in which the light weight aggregate is vermiculite.

4. The composition of claim 1 in which the nonionic detergent is a polyethylene glycol ether combined with 9 mo es of ethylene oxide.

Parts b Wei ht .2s 2.o .o 5 

2. The composition of claim 1 further comprising one to five parts by weight of polyvinyl acetate.
 3. The composition of claim 1 in which the light weight aggregate is vermiculite.
 4. The composition of claim 1 in which the nonionic detergent is a polyethylene glycol ether Combined with 9 moles of ethylene oxide. 